Corrugated Pipe Outer Wrap for Smooth Backfill and Lower Weight
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Solution Overview
Problem
Corrugated pipes face challenges with increased backfill work due to their valleys, and triple wall corrugated pipes suffer from higher costs, weight, and thickness.
Innovation Solution
Applying an outer wrap made of fibers and plastic to the corrugated pipe, which spans the corrugation crests to produce a smooth outer surface, thereby addressing the backfill issues and reducing material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If triple wall corrugated pipe is used to reduce backfill work, then the outer surface becomes smoother and easier to backfill, but the pipe weight, thickness, and production cost increase significantly
Solution Approach 1:
The pipe structure is segmented into distinct functional layers: the corrugated structural layer provides mechanical strength and radial stiffness, while the separate smooth outer wrap layer provides backfill efficiency. This segmentation allows each layer to be optimized independently, avoiding the need for a thick triple-wall structure.
Solution Approach 2:
The pipe combines different materials strategically: the corrugated pipe body (typically HDPE) provides structural integrity, while the outer wrap uses a smooth plastic material to create an easy-to-backfill surface. This composite approach achieves both structural and operational requirements without the excessive weight and cost of triple-wall construction.
2Ease of operation
If triple wall corrugated pipe is used to reduce backfill work, then the outer surface becomes smoother and easier to backfill, but the production material cost increases significantly
Solution Approach 1:
The manufacturing process is segmented into two independent stages: first producing the corrugated pipe body, then separately applying the smooth outer wrap. This allows use of cost-effective materials for the structural layer while adding only the minimum necessary material for backfill efficiency, reducing overall material costs compared to triple-wall pipe.
Solution Approach 2:
The smooth outer surface function is extracted from the structural pipe body and implemented as a separate wrap layer. This allows the main pipe to be made from cost-effective corrugated material while adding only a thin, inexpensive wrap layer for backfill efficiency, rather than requiring expensive triple-wall construction.
3Strength
If corrugated pipe with deep valleys is used, then radial stiffness and structural integrity are provided, but additional work is required to fill the valleys during construction
Solution Approach 1:
The pipe structure is divided into two functional segments: the corrugated outer wall provides radial stiffness and structural integrity, while the smooth inner surface (or smooth outer wrap) eliminates backfill problems. This segmentation allows both deep corrugations for strength and smooth surfaces for easy backfilling to coexist.
Solution Approach 2:
Different surface qualities are applied to different locations: the outer corrugated surface maintains deep valleys for structural stiffness, while the inner surface (or wrapped surface) is kept smooth where it contacts backfill material. This local differentiation resolves the contradiction between structural requirements and construction ease.
Data Source
AI summary
This disclosure relates generally to corrugated pipe, and more particularly to corrugated pipe with an outer wrap. In one embodiment, a pipe includes an axially extended bore defined by a corrugated outer wall having axially adjacent, outwardly-extending corrugation crests, separated by corrugation valleys. The pipe also includes an outer wrap applied to the outer wall. The outer wrap may include fibers and plastic. The outer wrap may span the corrugation crests producing a smooth outer surface.